Carmanah R829 User manual

OWNER’S MANUAL
Solar LED School Zone Beacon – Model R829
The world’s most advanced solar LED school zone beacon.
No external wiring or bulb replacement.
Maintenance-free for up to 5 years.
© November 7, 2006, Carmanah Technologies Corp.
www.carmanah.com
Technical Support: [e-mail]
Toll Free in North America: 1 [phone]
International: + [phone] | Fax: + [phone]
R829 – 37234

Owner’s Manual | R829
3
Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
Table of Contents
1.0 Introduction.............................................................................................................4
1.1 How It Works......................................................................................................4
2.0 Component Identification....................................................................................5
3.0 Tools and Materials Required.............................................................................6
3.1 Tools Required...................................................................................................6
4.0 Product Assembly and Installation....................................................................6
4.1 Selecting a Pole .................................................................................................6
4.2 Installing the R829 Switch Enclosure..................................................................7
4.3 Creating a Concrete Base ..................................................................................7
4.4 Removing the Solar Panel and Battery Covers...................................................7
4.5 Preparing the Solar Panel Module......................................................................7
4.6 Locate the Signal Head(s) and Sign...................................................................8
4.7 Wiring the Switch Enclosure...............................................................................8
4.8 Mounting the Head Assembly.............................................................................8
4.9 Erect the Pole.....................................................................................................9
4.10 Install the Upper Signal Head.............................................................................9
4.11 Installing the Lower Signal Head (if equipped)....................................................9
4.12 Connect the Batteries.......................................................................................10
4.13 Install Bird Deterrents on the Module Housing..................................................10
4.14 Attach the Solar Panels to the R829 Electronics...............................................11
4.15 Final Adjustments.............................................................................................11
5.0 Maintenance and Product Care ........................................................................12
6.0 Troubleshooting................................................................................................12
7.0 Service and Additional Products......................................................................13
7.1 Customer Service and Warranty.......................................................................13
7.2 Additional Products ..........................................................................................13
8.0 Product Specifications......................................................................................14
9.0 Appendix A – R829 Quick Start Guide .............................................................15
10.0 Appendix B – R829 Calendar Configuration Instructions...............................18

Owner’s Manual | R829
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Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
1.0 Introduction
Thank you for purchasing the Carmanah Model R829 school zone warning beacon, “the world’s
most advanced solar-powered LED school zone beacon.” Using LED illumination, the unit is
designed to operate flawlessly with no scheduled maintenance (other than routine cleaning) for
up to 5 years.
Combining advanced electronics and software with an innovative, patented combination of solar-
power and LED technology, the Model R829 has been designed to operate under all
environmental conditions at most locations throughout North America.
1.1 How It Works
Unlike programmable time clock systems, the R829 is programmed using an intuitive Windows-
based graphical user interface. The settings can be easily transferred to multiple R829 units.
Uploading the programmed settings occurs on site quickly and efficiently via a wireless link.
The R829 is completely power-autonomous - no wiring to an external power supply is required.
This allows a simple, low-cost installation even in locations where external power is unavailable.
It operates using solar-charged batteries that are maintenance free for up to five years when
properly installed.
The R829 can be ordered with one or a pair of flashing lights for each unit. When there are two
flashers, these can be mounted as a vertical dual flasher, a horizontal dual flasher, or a bi-
directional flasher depending on location requirements. When activated, drivers will see the lights
as a “bouncing-ball effect.”
Refer to the R829 School Zone Beacon Quick Start Guide in Appendix A or the School Zone
Calendar Configuration applications help files in Appendix B, and also included in the
programming software, for detailed information on setting up and uploading a custom-
programmed calendar to the R829.

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Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
2.0 Component Identification
1. Head Module.
2. Solar Panel.
3. Radio Antenna.
4. Signal Head (one or two).
5. Signal Head Mounting Bracket.
6. Sign (not included).
7. Pole (not included).
1
2
3
4
4
5
5
6
7

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Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
3.0 Tools and Materials Required
It is a good idea to begin the installation process in the shop. Take the time to read through this
manual to determine what tasks can be completed in the shop prior to the field installation portion
of the job.
Note: This product requires a concrete base that is designed for the pole to be used. Ensure
that this base is prepared beforehand.
3.1 Tools Required
•Socket set
•Drill and drill bits
•Screwdrivers
•Fine-tip felt marker
•Tap and die set
•Fish tape
•12-15 ft. ladder
•Level
•Knowledge of local latitude
•Compass (to measure direction)
•Compass (to measure angles)
4.0 Product Assembly and Installation
Installation time is approximately one hour in the shop and two hours in the field per R829
system. No trenching, external cabling, traffic disruption or site remediation required. Once
installed, the R829 is designed to operate for up to 5 years with virtually no maintenance other
than routine cleaning. After approximately 5 years, battery replacement will be required.
4.1 Selecting a Pole
Typically, a 10-foot “Type1” pedestrian pole is used for the installation. A “Type 9”, with a mast
arm for an over the road configuration or any other pole that has a 4” to 4.5” OD top cap, can also
be used.
Note: If a 4” OD pole is being used, longer bolts will be required than those provided.
Figure 1

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Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
4.2 Installing the R829 Switch Enclosure
Drilling the holes for the switch enclosure hardware is typically much easier to do while the pole is
in the shop. This should make the final installation in the field go quicker.
Ensure that the location of the switch enclosure will not interfere with the signal heads and
signage when they are later installed (see Figure 2).
Drill and tap two holes for mounting the plate. Drill 5/8” hole for the wire, then de-burr the edges
to avoid damaging the wires during installation.
4.3 Creating a Concrete Base
As shown in Figure 3, a concrete foundation with the necessary mounting hardware has been
poured prior to pole installation. The procedure for doing this is outside the scope of this manual.
4.4 Removing the Solar Panel and Battery Covers
First remove the cover with the solar panels from the top of the head module, and then remove
both covers from the two battery modules (see Figure 4).
4.5 Preparing the Solar Panel Module
Turn the solar module upside down to prepare it for installation. Prop up the end of the R829 that
has the radio antenna (see Figure 5) to ensure that this delicate component is not damaged
during assembly. One of the battery covers can be used as a support.
Figure 2
Figure 3
Figure 5
Radio Antenna
Solar Module
Figure 4
Battery Cover

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Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
4.6 Locate the Signal Head(s) and Sign
Before drilling any holes for mounting the signal head(s) or signs, do the layout for the locations
of the signal head(s) and sign at this time. See the layout in Figure 6 as an example.
Once the location of the signal head(s) and sign are determined, drill a hole to allow the wiring to
go from the lower signal head, through the pole, up to the solar module. The hole for the wiring
should be large enough to allow the use of a fish tape during installation.
Note: De-burr all wiring holes to eliminate any sharp edges that could damage the wires during
installation.
4.7 Wiring the Switch Enclosure
Use a fish tape to run the longest wire from the solar module head to the switch enclosure.
Carefully connect the switch enclosure wire to the wire running down from the solar module head
to the switch box through the mounting pole and then thread it into the pole so that it won’t be
pinched. Fasten the switch enclosure to the mounting pole.
Carefully thread the longest signal head wire through the mounting pole down to the location of
the lower signal head. Leave the wire dangling outside the pole. It will be used later when
installing the signal head.
4.8 Mounting the Head Assembly
Install the head assembly on the top of the pole before raising the pole into position (see Figure
8). Do this with caution so that the wiring is not pinched between the top cap and the pole.
Finger tighten the bolts that secure the top cap to the pole. Final tightening will happen at the end
after the solar panels are correctly oriented for maximum solar charging.
Note: If a 4” OD pole is being used, longer bolts will be required than those provided.
Figure 6
Figure 7

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Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
4.9 Erect the Pole
Assuming that the pole base is already in place, stand the pole upright and bolt it to the base
using the mounting hardware (see Figure 9).
4.10 Install the Upper Signal Head
Loosen the bolts, which hold the top cap to the pole so that the top cap can be rotated. Open the
cover of the top signal head and install the unit onto the upper elbow as shown in Figure 10.
Hand-tighten the nut for now.
Locate the bottom bracket as shown in Figure 11 and, as with the top elbow, tighten the nut finger
tight for now. The bottom bracket can be fastened to the pole with bolts or stainless steel straps.
Connect the signal wire from the head assembly to the signal head and close the cover.
4.11 Installing the Lower Signal Head (if equipped)
The wire for the lower signal head should already be hanging out of the hole in the pole. Feed
the wire through one of the brackets and fasten the bracket to the pole with bolts or stainless
steel straps.
Figure 8
Figure 9
Figure 10
Figure 11
Upper El
bow

Owner’s Manual | R829
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Carmanah Technologies Corp. Copyright © 2006
Document number: MAN_ROAD_R829 Owner's Manual 37234_vC
Last revised: November 7, 2006
Open the cover of the signal head, and install the unit onto the elbow. Finger tighten the nut.
Locate the bottom bracket and tighten the nut finger tight. The bottom bracket can then be
fastened to the pole with bolts or stainless steel straps.
Connect the signal wire from the solar panel module to the signal head and close the cover.
4.12 Connect the Batteries
Remove the cover from the control module and rotate the head unit so that the connection points
are facing the installer and the wiring label is visible.
Each battery has two connectors. With the harnesses facing the installer, connect the female
terminal of the right battery to the male terminal of the left battery. Connect the male terminal of
the right battery to the control module. A label inside the control module indicates the connector
location.
Note: If the above procedure is followed correctly, the left battery will have an unused or “extra”
harness.
4.13 Install Bird Deterrents on the Module Housing
The bird deterrents discourage birds from using the top edge of the R829 as a perch, thus
ensuring that the solar panels remain as clean as possible.
Place the top cap with solar panels onto a stable work area. Attach the three bird deterrents with
sheet metal screws, using the predrilled holes on the top cap as a means of identifying their
location.
Figure 12
Figure 13
Figure 14